Reinforcing Element With Localized Expandable Material
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Solution Overview
Problem
Existing reinforcing elements for motor vehicle structural components with cavities face challenges in preventing excessive foaming, which leads to unwanted material penetration into undesired regions, making it difficult to seal, reinforce, and insulate effectively, especially in irregularly shaped or narrow cavities.
Innovation Solution
A reinforcing element with a carrier having side walls and an intermediate member, where an expandable material with a controlled expansion rate is strategically applied only on specific regions of the side walls, allowing it to foam within a predefined zone, preventing unwanted material dispersion and optimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expandable material is applied on the entire outer side of side walls, then bonding area is increased, but excessive foaming occurs and material penetrates into undesired regions
Solution Approach 1:
The patent applies expandable material only to specific regions (first regions) of the side walls rather than the entire outer side. This local application strategy ensures bonding occurs only where needed while preventing excessive foaming in other areas, thus resolving the contradiction between bonding reliability and foaming control precision.
Solution Approach 2:
The side walls are divided into different regions: first regions where expandable material is applied for bonding, and second regions where no material is applied to prevent unwanted foaming. This segmentation allows controlled foaming in designated zones while avoiding penetration into undesired regions.
2Strength
If expandable material is applied extensively, then reinforcement coverage is improved, but material usage increases and costs rise
Solution Approach 1:
Expandable material is applied only to first regions of the side walls where bonding and reinforcement are actually needed. This localized approach maintains sufficient reinforcement strength while significantly reducing material usage compared to extensive application across the entire side wall surface.
Solution Approach 2:
Instead of applying material excessively to ensure full coverage, the patent uses partial action by limiting application to specific first regions. This provides adequate reinforcement where needed while avoiding the material waste associated with excessive application.
3Stability of the object's composition
If side walls are oriented perpendicular to demolding direction, then structural stability is maximized, but injection molding demolding becomes difficult
Solution Approach 1:
The side walls are oriented at an angle (α) relative to the demolding direction rather than being perfectly perpendicular. This asymmetric orientation with respect to the demolding direction facilitates easy removal of the reinforcing element from the mold while maintaining sufficient structural stability through the angled configuration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively prevents excessive foaming, ensures the expandable material remains within desired regions, reducing material waste and costs, while providing efficient reinforcement and insulation of cavities in motor vehicle structural components.
Implementation Method 1
an expandable material (13) which has an expansion rate of not more than 500 % and which is arranged on an outer side of each of the side walls
Data Source
AI summary
A reinforcing element for reinforcing a structural element of a motor vehicle includes a carrier and an expandable material arranged thereon. The carrier has a first side wall and a second side wall, and an intermediate member connecting the side walls. The reinforcing element is produced by an injection molding process, wherein the side walls are oriented substantially in a demolding direction of the injection molding process. The side walls each have on their outer sides a first region and a second region, wherein the first region is covered with expandable material and the second region is not covered with expandable material.